Machine design, tập 83, số 16, 2011

High-techZeppelins page 42 CONVERTING GLASS BOTTLES TO PET, page 23 WHEN SOLAR ARRAYS CATCH FIRE, page 50 HOW TO SELECT PNEUMATIC CYLINDERS, page 56 AIR CUSHIONS THAT SELF-ADJUST, page

High-tech

Zeppelins

page 42

CONVERTING GLASS BOTTLES TO PET,

page 23 WHEN SOLAR ARRAYS

CATCH FIRE, page 50 HOW TO SELECT PNEUMATIC CYLINDERS, page 56 AIR CUSHIONS THAT SELF-ADJUST, page 64

September 22, 2011

A Penton Media PublicationTune in to EngineeringTV.com

Stop Your Fretting

•Superior Reliability

•Quickest Delivery Available

Baldor
Dodge ® Grip Tight ® Adapter ball bearings are

the solution for damage-free shafting, reduced vibration

and greater inventory cost savings Our unique push/

pull adapter system provides fully-concentric 360 °

shaft contact for quick installation or removal.

Off-the-shelf and shaft ready, Grip Tight Adapter ball

bearings are proven to reduce labor/maintenance

costs and stop your fretting once and for all.

dodge-pt.com baldor.com 479-646-4711

©2011 Baldor Electric Company

RS# 101

W e s t b r o o k • L o n d o n • P a r i s • F r a n k f u r t • M i l a n • S t o c k h o l m

Ultra Lights

8000 psid 125" Dia Lee Chek 0.75 Grams

The Lee Company

2 Pettipaug Road Westbrook, CT 06498 USA

860-399-6281 www.theleeco.com

With today's high cost of fuel, it's never been more important to shed aircraft weight Fortunately, The Lee Company had plenty of runway with this challenge – by making it our priority 60 years ago.

As a result, our Ultra Light products are now even smaller and lighter – some weighing less than the page you're reading And of course, they're just as reliable as ever Lee Plugs ® , restrictors, valves and screens are unsurpassed in offering breadth of choice and peace of mind No one offers more experience designing, manufacturing and ensuring zero-defect, as-promised quality Which helps explain why we're

on board every commercial and military aircraft that leaves the ground today.

Call today for the latest edition of our Technical Hydraulic Handbook, and discover hundreds of ways

to put your next design on a low fuel diet.

RS# 102

pneumatics technology guide

pneumatic cylinders come in thousands

of versions here are some tips for choosing the best one for the job.

Authored by:

Sheila Campbell Product Manager - Actuators

Norgren Inc

Littleton, Colo

Edited by Kenneth J Korane

ken.korane@penton.com Key points:

• Pneumatic cylinders come in many basic versions.

• All cylinders can be tweaked to better fit an application.

• Custom designs can perform better and save money when standard cylinders don’t fit the job.

guidelines for

SeleCting CylindeRS

Clean, compact, durable, and fast-acting air cylinders are workhorses on packaging machinery.

September 22, 2011 mACHINe Design.com 56

pneumatics technology guide

A common goal throughout the industrial world is to boost productivity For pneumatic devices, this often requires running actuators as fast as pos- sible without introducing excessive shock and vibration to products and equipment.

To reduce an actuator‘s impact energy, engineers rely on two common types

of integrated cushioning — bumpers and air cushions Flexible bumpers are energy, limiting them to slow-speed, small-load, or short-stroke applications.

Operating with higher loads and speeds demands additional cushioning to avoid damaging the cylinder and machine Engineers generally use air cush- ions for end-of-stroke damping in these cases.

Unfortunately, these are not plug-and-play devices Experienced nance technicians must adjust the air-cushion valves, and that depends on the may run slower or face unacceptable impact loads.

mainte-A new type of air cushion automatically adapts to changing conditions, eliminating the headache of manual adjustments It offers the potential to in- crease productivity and reduce maintenance costs.

Cushion basics Air cushions are variable-orifice air dashpots As the cylinder cycles, a spud

on either side of the piston closes a passage to the main piston chamber This traps air in the cylinder end cap and bleeds it off through a small port con-

self-adjusting air cushions let machines run smoother and faster.

Request free information vi a our Reader Service Web site at www.machinedesign.com /rsc

trolled by a needle valve The cylinder traps a fixed volume performance.

For any given set of conditions, there is generally only

a small window of needle-valve adjustments that provide acceptable cushioning Closing the needle valve too far re- sults in high initial reaction forces, which slow the load too cycle time.

Open the needle valve too far, however, and the trapped air does not generate sufficient back pressure The load

is properly set, any change in weight, pressure, or ity affects cushion reaction and means the valve must be readjusted.

veloc-Self-adjusting cushions Recently developed self-adjusting cushions eliminate the need for manual adjustment In principle, they work the same way as conventional cushions, except the cush- ton, not past an adjustable needle valve.

The geometry of these notches is critical

Longitudi-cylinder cushions adapt

• New self-adjusting air cushions adapt

to changing loads and operating conditions.

Adjustable air cushion

Adjustable air cushions control piston speed by throttling exhaust air (red) through a needle valve.

September 22, 2011 mACHINe Design.com

Access our Reader Service Web site to quickly find and request information on the products and services found

in the pages of M ACHINE D ESIGN www.machinedesign.com/rsc

56

64

Bye-bye blimps

Willkommen Zeppelins

Goodyear Tire & Rubber Co is

upgrading its fleet of blimps, turning

them in for larger, more-advanced

Zeppelins

Heading off accidental fires

in solar arrays

Fighting a PV panel fire is hazardous

enough without having to stand in

water next to a 600-Vdc power source

that can’t be turned off

Guidelines for

selecting cylinders

Pneumatic cylinders come in thousands

of versions Here are some tips for

choosing the best one for the job

Cylinder cushions

adapt on the fly

Self-adjusting air cushions let machines

run smoother and faster

SEPTEMBER 22, 2011 MACHINE Design.com

2

Directional Solenoid Valve

5-port, 4-way, 2-position, 1/4” NPT,

$115.47

42007401

$62.48 6124K513

$74.80 7390K17

McMaster-Carr

$93.80 3JCN6

$108.70 4ZK92

Product Description

Combination Filter/Regulator

1/4” NPT, gauge, mounting bracket

CHECK OUT OUR PRICES ON VALVES and FRL

Check around! You’ll see we’ve got great prices on ALL the components you need to complete a pneumatic

Tubing and Hose

• Bulkhead, straight, tee,

elbow, Y, cross and

triple branch unions

Fittings

• Manual hand valves,

stop, check, meter-in, meter-out and inline

Stainless Steel Air Cylinder

2 inch bore, 4 inch stroke, double acting, pivot/double end mount

Stainless Steel Air Cylinder

3/4 inch bore, 1 inch stroke, single acting spring return, nose mount

Stainless Steel Air Cylinder

1-1/16 inch bore, 6 inch stroke, double acting, pivot/double end mount

CHECK OUT OUR PRICES ON CYLINDERS

RS# 103

For customized article reprints and permissions please contact: Penton Reprints, 1-888-858-8851, e-mail at reprints@pentonreprints.com or visit pentonreprints.com.

Editorial content is indexed in the Applied Science Technology Index, the Engineering Index, SciSearch and Research Alert Microfilm copies available from National Archive Publishing Company (NAPC), 300

N Zeeb Rd., P.O Box 998, Ann Arbor, MI 48106-0998, Ph: 734-302-6500 or 800-420-NAPC (6272), extension 6578.

Permission to photocopy is granted for users registered with the Copyright Clearance Center (CCC) Inc to photocopy any article, with the exception of those for which separate ownership is indicated on the first page of the article, provided that the base fee

of $1.25 per copy of the article, plus $.60 per page is paid to CCC, 222 Rosewood Dr., Danvers, MA 01923 (Code No 0024-9114/11 $1.25 + 60).

Subscription Policy: M ACHINE D ESIGN is circulated

to research, development, and design engineers primarily engaged in the design and manufacture

of machinery, electrical/electronic equipment, and mechanical equipment To obtain a complimentary subscription see our Web page at submag.com/sub/

mn For change of address fill out a new qualification form at submag.com/sub/mn.

Printed in U.S.A., Copyright © 2011 Penton Media, Inc All rights reserved M ACHINE D ESIGN (ISSN 0024-9114) is published semimonthly except for a single issue in January and July by Penton Media, Inc., 9800 Metcalf Ave., Overland Park, KS 66212

Paid subscriptions include issues 1-21 Issue No 22 (OEM Handbook and Supplier Directory) is available at additional cost Rates: U.S.: one year, $139; two years,

$199; Canada: one year, $159; two years, $239; All other countries: one year, $199; two years, $299 Cost for back issues are U.S $10.00 per copy plus tax, Canada $15.00 per issue plus tax, and Int’l $20.00 per issue Product Locator, $50.00 plus tax Prepaid subscription: Penton Media (M ACHINE D ESIGN ), P.O Box 2100, Skokie IL 60076-

7800 Periodicals Postage Paid at Shawnee Mission, Kans., and at additional mailing offices.

Can GST #R126431964 Canadian Post Publications Mail Agreement No.40612608 Canada return address: Bleuchip International, P.O Box 25542, London, Ont., N6C 6B2.

Digital subscription rates: U.S.: one year, $69; two years, $99; Canada: one year, $79; two years, $119; All other countries: one year, $99; two years, $149 POSTMASTER: Send change of address notice to Customer Service, M ACHINE D ESIGN , P.O Box 2100, Skokie,

IL 60076-7800.

ON THE COVER

An LZ N07-101 Zepplin

EDITORIAL

Food for thought: The distance

between a field and your plate

EDITORIAL STAFF

LETTERS

SCANNING FOR IDEAS

Hybrid sweeper-scrubber goes green

Gas springs provide just the right force

4

Globa

l, CF

S, T heega

K ro nes , B

ng , W

olf , M

ed iSeal

, T -P ack,

riani , L og

Te cn ome

S ACMI,

Has sia- Red

K ro nes , B

uhm ann Pa

res Vision

, Ma kro L

, Kö rbe r Me

a, De

La Ba

llin a

Indu str ie,

P ackS

CF S, Theega

rten Pac tec

, YK , Ila pa

uhm ann Pa

Be one of them and experience the difference

More than 200 packaging

controls.

South Hall / Booth 5111

www.br-automation.com

RS# 104

New bearings catalog

A new catalog from igus covers

plastic bushings, spherical bearings, and linear bearings and guides It helps users select products by in- dustry, application, or criteria such

as load, temperature, friction, and wear It also includes drawings and

a number of new products Get it at www.igus.com/quickorder.

Enclosures en español

Pentair Technical Products, Hoffman has a new Web site

(http://hoffmanonline.com/espanol) offering a wide range of Spanish- language literature on engineered enclosures It includes a specifier’s guide, product catalog, a white pa- per on global standards, renewable- energy brochure, and an interactive selection tool to calculate cooling requirements based on thermal load and enclosure size

Video demystifies battery insulation

Fabrico’s new video looks at

materi-als issues with lithium-ion, cadmium, and other advanced bat- teries It delves into electrical insula-

nickel-tion, electrical conductivity, thermal management, EMC/EMI shielding, and packaging for cushioning and protection View it at www.fabrico com/markets-applications-batteries htm.

Pumps and compressors

The new Thomas Global Catalog

has updated specs and mance data on hundreds of articu- lated piston, diaphragm, rotary, and linear oilless air compressors/ vacuum pumps; and peristaltic, lin- ear, and diaphragm liquid pumps Selection guides help users quickly find the right product by technol- ogy and model View or download a copy at www.gd-thomas.com

perfor-Guide to inspection software

Delcam has an online guide

relat-ing new developments in its tion software The site includes a series of videos on capabilities, en- hancements to GD&T functions, and how to speed analysis, efficiently reuse measured data, and handle point-cloud data View the site at www.delcam.tv/pi2011/lz

inspec-Micro vehicle is tough as nails

At AUVSI Unmanned Systems 2011, QinetiQ debuted their latest micro

unmanned ground vehicle (MUGV) for military and first-responder

robotic missions The Dragon Runner 10 weighs less than 10 lb — light enough to throw through windows, into rooms, and off rooftops The DR 10 is built to withstand harsh environments and gather data through

a multitude of interchangeable day and night sensors, radios, cameras, and robotic

arms Learn more at www engineeringtv.com/video/ Dragon-Runner-10-Easier-to- Thro.

Product and supplier database

M ACHINE D ESIGN ’s OEM Supplier Directory is the place to find manufacturers and suppliers of products and services for the OEM The Directory includes more than 2,500 types of components and systems — everything from engineering software to dc motors, needle bearings, nuts and bolts, and hydraulic cylinders Information is grouped by technology: CAD/CAM, electrical/electronic, fastening/ joining, fluid power, manufacturing processes, materials, and mechanical It’s intended to help design engineers make educated, informed purchasing and specification decisions Find it at http://directory.machinedesign.com.

6

Millions and Millions of Reasons

Together, we can deliver more uptime, more product innovations and a greater bottom

line value Connect with Parker for premier customer service and superior product

performance We are your choice for pioneering products like Robust Port Stud™,

Compact Spiral™ and Trap Seal® Parker also helps reduce equipment and machinery

downtime by increasing the speed and accuracy of acquiring replacements with our

exclusive PTS For more information on our 250 million + reasons to choose Parker,

scan the QR code with your smart phone or visit www.parker.com/oneconnection

RS# 106

The Pack Expo trade show is about to kick off and is notable because it caters to the packaging industry The packaging industry, in turn, largely revolves around the packaging of food So it might be appropriate to examine the recent trend toward hand-wringing over “food miles.” The idea is that the longer food travels before it hits your plate, the more energy dissipated and greenhouse gases generated

At least according to popular mythology The truth of the matter is that most energy and greenhouse gases associated with food go into its production, not its transportation And that goes equally for food bought at the local farmers’ market as well as for that picked from grocery-store shelves

The issue of food miles has been thoroughly investigated by two mental engineers at Carnegie Mellon University in the U S and by the Dept for Environment, Food and Rural Affairs in the U K CMU researchers Christopher Weber and H Scott Matthews found that the food-production phase contributed 83% of the average U S household’s annual carbon footprint for food consump-tion Transportation as a whole accounted for only 11% of greenhouse-gas emis-sions associated with food And final delivery from producer to retail contributes only 4% of that 11%

environ-It also emerges that transport by ship, rail, and air freight over long distances

is efficient compared with trucking food a comparatively short distance to its final destination The trucking phase is responsible for 71% of the total green-house gases generated while transporting food Wholesaling and retailing op-erations accounted for just 5% of overall emissions

CMU researchers as well found that globalization has increased the distance food travels by around 25% since 1997 But this has boosted greenhouse-gas emissions associated with transport by a mere 5%, simply because ocean ship-ping is far less energy intensive than overland trucking

In the U K., DEFRA examined the “food miles” question partly to see whether a “buy-local” movement in that country made any sense DEFRA un-covered percentages similar to those of the CMU research, and also discovered that “buying local” could lead to more greenhouse-gas emissions rather than less The reason is that a lot of produce in the U K must be grown in green-houses rather than in open fields The energy debt of a greenhouse is a deal-killer, greenhouse gas-wise

The situation isn’t much better for produce grown in U K fields that must

be put in cold storage until it is eventually consumed U K residents generate fewer greenhouse gases shipping fresh apples in from New Zealand than putting British apples in a cooler And when it comes to milk, U K dairy farmers use twice as much energy to produce a metric ton of milk solids than New Zealand farmers, says DEFRA

The lesson from all this is that food should be grown where it is most nomically virtuous to do so And the packaging industry needn’t worry about

eco-“buy-local” movements cutting into the need for its products

— Leland Teschler, Editor

Food for thought:

The distance between a field and your plate

Congratulations to Don Schimizzi, J Harboy, Rich Werth, Sasa Pudar, and Bradley Miller They each won a $100 American Express gift card as top scorers for August in our World’s Smartest Design Engineer contest Challenge yourself now at www.smartestdesignengineer.com and see if you

can top the scoreboard next month!

Keep Your Machine Running!

Festo’s VTUB pneumatic manifold is not only

reliable, but is also very easy to maintain.

Simply mount valves with one single screw.

Designed for corrosion resistance, your machine

will be running longer and faster with the VTUB.

Global manufacturer of process control and factory automation solutions

For more information:

Call: 1-800-Go-Festo 1-800-463-3786 www.festo.com/us/vtub

RS# 108

for OEM Applications

AC Motor Drives

Chassis/IP-20, Nema 1/IP-40 and Nema 4X/IP65 models

Conveyors • Pumps • Packaging Machines • Ovens • Mixers

• Blowers • Fans • Door & Gate Openers • Treadmills

“A Complete Line of Motor Drives”

Provides Speed Control for:

AC Induction, Brushless DC & PSC Motors Subfractional thru 5 HP

115, 208/230, 400/460 VAC – 50/60 Hz 1Ø & 3Ø Input

* Rated 1.0 Amp output with non-isolated input, 1k qty

Power Transmission Products

38 River Road, Uxbridge, MA 01569

MITRPAK right angle,

three-way, and

counter-rotating spiral bevel drives

are interchangeable with

Boston Gear, Hub City, Browning…

and we guarantee 24-hour shipment.

For complete specifications and

CAD files, log onto www.mitrpak.com ,

or call us at 800-648-7725 Learn

how MITRPAK minimizes backlash by

using locknuts, rather than conventional

spacers and rings.

* Contact us for details.

Editorial Production Manager

Randall L Rubenking, Art Director

1300 E 9th St Cleveland, OH 44114-1503 RS# 110

RS# 109

SEPTEMBER 22, 2011 MACHINE Design.com

10

DŽƟŽŶdĞĐŚŶŽůŽŐLJ &ŝďĞƌKƉƟĐƐ ůĞĐƚƌŽŶŝĐ^LJƐƚĞŵƐ нϭͲϱϰϬͲϱϱϮͲϯϬϭϭ ϬϬͲϯϯϲͲϮϭϭϮ;h^ͿŵĐŐΛŵŽŽŐ ĐŽŵ

Looking for more? Scan with your

smartphone to view our complete

product offering and specifications.

Aerospace Products:

9 ^ůŝƉZŝŶŐƐ9dŽƌƋƵĞDŽƚŽƌƐ

9ZĞƐŽůǀĞƌƐ9 &ŝďĞƌKƉƟĐZŽƚĂƌLJ:ŽŝŶƚƐ9 ƵŝůĚͲdŽͲWƌŝŶƚ^ŽůƵƟŽŶƐ

RS# 111

• The information on Brinell ness did not mention the stan-dard ball and standard loads for

hard-a Brinell hhard-ardness tester The bhard-alls should be 10.0 mm in diameter and made of hardened steel and tungsten carbide Balls that aren’t

10 mm should meet ASTM E 10 quirements The test uses loads of

re-500, 1,000, 1,re-500, 2,000, 2,re-500, and 3,000 kgf And the 500-kgf load is for testing relatively soft metals such as copper and aluminum al-loys The 3,000-kgf load is mainly used to test steels and cast irons

• The article left out the range of the most accurate readings (the minimum and the maximum val-ues) for Brinell and Rockwell (HRB

Details, details, details

The recent article on hardness

testing was interesting and

use-ful (“Getting Help from

Hard-ness Testing,” July 7) It provides

technical information on various

types of hardness, one of the

im-portant mechanical properties of

materials in general, especially

for metal cutting

But there are a few discrepancies:

• The definition of “ANSI” 4130

steel is incorrect ANSI is an

acronym for the American

Na-tional Standards Institute

Cor-rect definition of this grade of

steel is AISI/ASTM 4130 (AISI

stands for American Iron and

Steel Institute, and ASTM stands

for American Society for Testing

and Materials)

• The description of the steel heat

treatment that increases

hard-ness left out the critical fact that

for annealing, the rate of furnace

cooling (so many degrees per

RS# 112

Produce smart phones faster with high speed bearings

Ever wonder how producers of extremely advanced consumer electronics, like smart phones, manage to keep launching new generations of these products

at such a ferocious tempo with consistently high quality?

SKF product manager Satyen Bohidar and SKF’s sales team have part of the answer – SKF-SNFA high-speed super precision bearings They allow the machine tools used for manufacturing key components of these products to run flawlessly and precisely at up to 60.000 rpm 365 days

The Power of Knowledge Engineering

Milling spindle running

at 40.000 rpm

Satyen Bohidar, SKF Product Manager SKF-SNFA high-speed

bearings

RS# 113

PHONE 800 520 4769, 918 254 9872

FAX 918 254 2544

EMAIL info@us.roxtec.com , www.roxtec.com

Cable entries made easy

 Complete light-weight kits

 Seals multiple pre-terminated cables in one opening

 Protects against water, dust and vibration

Multidiameter™ by Roxtec No more cutting off connectors Sealed to UL/NEMA and IP ratings

LETTERS

I recently filed the patent to cover this invention in the U S and Can-ada And we chose a name from the several hundred suggestions we re-ceived mostly due to the magazine article, the “Nail Shark.”

The response I got from the ticle was really inspiring I had e-mail from a great number of companies ready to buy several right away It turns out there is a whole industry that does nothing but take apart old buildings to recycle the wood They

ar-do it mostly by hand A gentleman I corresponded with from Habitat for Humanity said that they routinely buy and tear down old houses, and

if they could more economically take them apart, it would save them mil-lions every year

The first-round prototype built over this past year pulled out big and small nails and even a few dry wall screws The second version is just about ready to be prototyped

I have estimated that there may

“NailOut.” He enjoys building with wood but he says removing nails is too much work

and HRC) hardness numbers

• The information in the table

“Sample hardness ranges for

metals” is inaccurate A

tungsten-carbide ball indenter lets you

measure the hardness of

heat-treated steels up to a maximum

of 627 HB If the Rockwell

hard-ness is 105 HRB, scale C should

be used because numbers higher

than 100 are inaccurate If

hard-ness is less than 20 HRC, scale B

should be used for the same

rea-son, i.e., hardness numbers of 19

HRC and lower are inaccurate

Edmund Isakov

Nail remover update

The Sept 23 issue from last year

fea-tured a nail-pulling gun in the

Inven-tor’s Corner column It asked readers

to suggest names for the

soon-to-be-patented invention Here are some of

the letters we received, as well as an

update from the inventor

RS# 114 SEPTEMBER 22, 2011

MACHINE Design.com

14

Made in North America and in stock for immediate availability.

NFPA 79 compliant

SENSORS | NETWORKS/FIELDBUS | RFID | CONNECTIVITY | INTRINSIC SAFETY

RS# 115

RPS tackles your toughest motion applications The innovative, new Precision Roller Pinion System (RPS) from Nexen handles your most demanding linear motion control applications Simply put, no other motion system offers the combination of speed, positional accuracy, stroke length, load capacity and zero backlash performance Not to mention it’s also extremely quiet, 99% effi cient, and so refi ned it can run without lubrication Replace inferior rack and pinion, ball screw and belt drive technologies with higher performance and lower maintenance solution

Unlimited run lengths

Put some teeth

in your motion control

Learn more atwww.nexengroup.comCall 800.843.7445

± 5 μm (±0.0002")repeatability

Some serious sarcasm

I have been carefully reading all the articles associated with electric ve-hicles (EVs) There is a way to extend the range of EVs that is so obvious

I do not understand how everyone

is missing it All EVs should be signed with motors for propulsion on two wheels and alternators on two wheels to generate electricity Ergo,

de-we will greatly extend the range of EVs and save a lot of ergs

I feel sure that when this proposal

is turned into law by our Congress, sales of EVs will soar Having solved this problem, Congress can then ad-dress major other issues such as re-pealing some of those annoying laws

of physics and letting us buy descent bulbs

incan-Jeff Scanlon

In place of the example shown

in this article, I would suggest a two-step approach First, solve a truss that is statically determinate

by hand Then solve it by FEA Then solve a truss that is not statically determinate (i.e., something that involves additional relationships like Castigliano) before you solve

it by FEA After modeling and ing several simple problems such

solv-as this, you can progress to thing more difficult such as model-ing nonlinear behavior in FEA

some-Warren Merriman

350 psi of vacuum?

In an article on vacuum forming (“Vacuum-Formed Plastics Fool Filmgoers,” July 7), it said the tech-nicians “apply about 350 psi of vacuum.“ This doesn’t really make sense Maybe someone meant pressure?

John Matthews

be a demand for 250,000 or more in

the first few years There are between

1 and 2 million carpenters in the U S

and Canada, and nearly every one

I have spoken with said they would

buy one of these the first chance they

get.— Jake Kittell

A better way to learn FEA

I wholeheartedly concur with the

thrust of the recent FE Update

col-umn (“Surface Contact 101: Block

and Ramp with Friction,” July 7)

However, I think the example

cho-sen was way too difficult for

nov-ice FEA users During the 1980s,

I was a structural loads engineer

working on the Space Shuttle at

Rockwell The company

devel-oped a course for training new

us-ers on FEA that contained a series

of problems, each progressively

more difficult than the previous

one, that could be solved by hand

You could then model and solve

them using FEA

RS# 116

IT’S MOTION

CONTROL VERSUS

MOTHER NATURE

ON CENTRE COURT.

WHEN IT COMES TO HIGH PERFORMANCE MOTION CONTROL, MOOG EXPERTS ARE THERE

When design engineers sought the best way to control the new retractable roof at Wimbledon’s famed Centre Court, they turned

to Moog The result was an innovative all-electric installation that provides 148 axes of control via high performance electric actuators, servo motors, servo drives, closed-loop controls and software Now, more than 1,100 metric tons (1,212 tons) of steel and 5,200 square meters (17,060 square feet) of fabric move swiftly and safely to prevent rain delays

Moog’s combination of motion control expertise and world-class solutions

can make the difference for you too—no matter what industry you’re in

For more information call 866-580-7610.

©2010 Moog All rights reserved.

How can we improve your machine design?

View our Wimbledon video at http://info.moog.com/wimbledon/1

RS# 117

SCANNING FOR IDEAS

Edited by Stephen J Mraz

Hybrid sweeper-scrubber goes green

WANT MORE?

Focus on this code image using your smartphone and free software from www.

neoreader.com, and you will be connected to related content

on machinedesign.com.

http://tinyurl.com/4yrjq9t

Request free information vi

a our Reader Service Web site at

www.machinedesign.com

/rsc

The CS7000 sweeper-scrubber from Nilfisk-Advance, Plymouth, Minn (www.

advance-us.com), can use a variety of hybrid drives — LP gas/electric or diesel/

electric — for power There’s also an all-electric version And it uses electric motors

to eliminate most of the hydraulics commonly used on traditional ride-on cleaning

equipment

The hybrid version uses liquid propane or a diesel engine to drive a high-capacity

ac-brushless alternator which is hooked to a 36-V battery pack The batteries’

primary purposes are to provide supplemental peak load sharing

and to keep the machine working for a short time in case

the engine fails The 36-V power drives the ac

mo-tors for steering and propulsion, while

dc motors propel the

sweep-ers and scrubbsweep-ers All

the motors

are IP55 wash-down rated Engine speed adjusts to deliver all the power needed to

support various machine operating modes The hybrid machines use 50% less fuel

and emit fewer CO2 emissions

The all-electric version, dubbed 3Power, uses the same electric drives and delivers

5.4 hr of run time on a single charge, which is about 65% more run time than

compet-ing electric cleaners It relies on conventional lead-acid batteries

The vehicles use a cylindrical sweeper with a separate disc scrubber This lets the

cleaner sweep and scrub in one pass without putting cleaning

solu-tion into the debris hopper, keeping swept up debris dry An opsolu-tional

dust-suppression feature reduces airborne dust by 85% compared to

motorized side brooms And a nanofiber filter resists clogging

The cleaner-scrubber can be used for industrial buildings such as

warehouses, factories, and shipping facilities, and in outside areas such

as park grounds and parking lots

RS# 401

Polymer body panels won’t dent or corrode,

or damage surroundings

75-gallon corrosionproof recovery tank

Three-stage vacuum motor

7-cu-ft sweeper debris hopper

18

Hanover Park, IL 60133 Fax: (630) 295-8881 1-800-521-2045

San Jose, CA 95131 Fax: (408) 435 1850 1-888-562-4175

You have so many choices within each guide class

– the NB standards, unique guides.

*Optional fiber sheet shown installed.

Guide shown is from the SGL family within the NB Slide Guide product line.

NB’s Ultra Precise Slide Guides

Easily Pass Your ‘Multiple Choices’ Test

Ramsey, NJ 07446 Fax: 201-236-5112 1-800-981-8190

RS# 118

New! Contrinex Series 4050 photoelectric sensors with highly effective background suppression

Visit our Design Site at www.contrinex.com

Contrinex Inc

Old Saybrook, CT 06475 Toll free: (866) 289-2899

Fax: (860) 388-3574 E-mail: info_us@contrinex.com www.contrinex.com

Operating distance is independent of target color, shape or surface structure

• Long operating distance of 500 mm, with a setting range from 20 to 500 mm

• Distance set by a 3-turn potentiometer with position indication

• Rugged, small PBTP housing suitable for rough environments

• Red light beam considerably simplifies alignment

• Switching frequency of 500 Hz

• Outstanding optical characteristics provide a virtually negligible blind zone (< 1 mm at s = 300 mm) The Series 4050 features a

rugged 40 x 50 x 15 mm PBTP housing suitable for rough environments

SCANNING FOR IDEAS

Gas springs provide just the right force

Self-contained and maintenance-free gas springs from Ace Controls Inc.,

Farmington Hills, Mich (www.acecontrols.com), provide a range of forces to

provide controlled motion for lids, hoods, doors, panels, and machine guards

They are available in sizes from 15 to 28 mm in diameter with forces from 10 to

2,500 N They all have steel piston rods and cylinders, and grease chambers for

low break-away forces They work in any orientation, although mounting with

the rod down is preferred An internal valve lets the users adjust the force to an

application’s requirement When operating in hot temperatures, it is important

to note that for every increase of 18°F (or 10°C), spring force increases by 3.4%

RS# 402

RS# 119

Cylinder filled with high- pressure

orifice for defined extension velocities

Steel body

Treated steel rod

Grease chamber

Oil-zone filling for end position damping, and lubrication

20

RS# 120

REPORTER’S NOTEBOOK

Molded panel lets solar-powered

trash compactor catch rays

The design of a

solar-powered trash

compac-tor for city streets used

several plastic-molding

issues to make it practical

The original

compac-tor made by BigBelly

Solar in Needham, Mass.,

worked well but was

costly to manufacture

The Mack Molding Co.

in Arlington, Vt., worked

with BigBelly to address

the cost problems

To shield the solar

panel from the elements,

Mack injection molds a

clear cover from

high-impact, UV-resistant

polycarbonate resin on a

1,000-ton press The large

part must be perfectly

clear to expose the solar panel below

to the sun The 27.75 × 20.39 × 4.39-in

part is molded with just one gate to

avoid knit lines that would interfere

with sunlight hitting the solar cells

Mack also compression-molds side

panels and a hopper cover from

ther-moplastic olefin that has been 100%

recycled from car bumpers Wall

thick-nesses vary and the side walls are

thin-ner than the main wall The molding

gate was located on the thinner side

wall so that it is invisible after assembly

Mack conducted mold-flow analysis,

as well as experiments with tooling, to

set cycle time, temperature, and

injec-tion pressure It finalized a mold that

would give technicians more

control over the process The

tool design was also critical

in terms of the location and

direction of water lines

Engi-neers were able to downsize

the tool by using a hot runner

bar, which lets the part run

in a smaller press with better

economics

The trash bin in the

com-pactor is rotomolded of

low-density polyethylene resin

Mack fabricates the back panel and door out

of metal The unit can be custom painted, silk-screened with logos or other artwork, or vinyl wrapped with custom artwork

The point of equipping these trash ceptacles with solar power is to let service personnel make fewer stops to empty its 32-gallon bin The solar cells charge a bat-tery which provides all the power needed to periodically compact trash Thus, the recep-tacle can sit anywhere because it needn’t

re-Trash compactor… continued on page 27

Resources:

BigBelly Solar, (781) 444-6002,

www.bigbellysolar.com RS# 406 Mack Molding Co., (802) 375-0349,

www.mack.com RS# 407

For a video of the solar-powered trash compactor in action (shot sideways, unfortunately):

22

Barbecue sauce and wine give up on glass

Clear plastic bottles are nothing

new in food and beverage

packag-ing, but they are now being used

in markets where products were

traditionally tied to glass Many

companies are choosing bottles

made of polyethylene

terephtha-late (PET) because they are as clear

as glass and less likely to break

And customers see the bottles as a

greener alternative to glass

The wine market is one that has

been slow to adopt new forms of

packaging Many consumers still

believe wine should be packaged in

traditional 750-mL glass bottles with

foil-covered corks Nonetheless,

boxed wines and single-serve

bot-tles are becoming more common

This is especially true in

ven-ues like parks, concerts, sporting

events, and airplanes In these

areas, broken glass can be a

sig-nificant hazard, so vendors and

beverage companies have looked

to plastic

Fetzer, Hopland, Calif.,

Cecchetti Wine Co., Sonoma,

Calif., and Sutter

Home, St Helena,

Calif., are among

the companies that

FDA-approved silicon-oxide

coatings developed by KHS

Plas-max GmbH, Hamburg, Germany,

seal the containers from the inside

to keep contents from oxidizing and give PET-bottled wine the same shelf life as wines bottled in glass The film is less than 100-nm thick and removes easily during recycling

Eliminating the potential for bottles to break during shipping is

a major cost savings Another vantage is the lighter weight — PET containers weigh 1/6th that of glass bottles with the same volume — which saves transportation costs and cuts fuel consumption

ad-Sutter holds 38% of the serve market, which is expected

single-to amount single-to 2.2 million cases this year Fetzer is the tenth largest winery in the U S and a leading provider of copacking services PET… continued on page 27

And Cecchetti supplies Redtree

wines to Air Canada, British

Air-ways, and Continental Airlines,

and is exploring retail distribution

of 1-L PET-packaged wines in the Midwest

Another consumer product moving to PET containers from

glass is barbecue sauce Mrs

Griffin’s Barbecue Sauce, Macon,

Ga., has been a well-established brand in the southeastern U S

since 1935 It recently converted its 12-oz ring-neck and 32-oz decanter-style glass bottles to PET packages from Amcor and uses its existing filling lines

Mrs Griffin’s president and CEO

Resources:

Amcor Rigid Plastics, www.amcor.com Cecchetti Wine Co., www.cecchettiwineco.com Fetzer, www.fetzer.com

KHS Plasmax GmbH, www.khsplasmax.com Mrs Griffin’s Barbecue Sauce, www.

griffinsbbq.com

Sutter Home, www.sutterhome.com

Converting serve 187-mL wine bottles from glass

single-to PET makes the containers more convenient for consumers, who can use them wherever broken glass is a hazard

They also save breakage and fuel costs in shipping and are more easily recycled than glass.

When

it matters

GORE® Electronic Materials

Enhance performance and

increase design flexibility

in your electronic systems with

the latest EMI shielding and

RF grounding solutions from Gore.

Wideband power amp

Impedance matching

Rectifier Interdigitated electrodes

A schematic of the system used to power Purdue’s implantable transducer.

Visible in this artist’s representation

of the IMOG are components such as the ultrasonic receiver, rectifier circuitry, electrodes, and ion-exchange membrane

generator harvests power from

ultrasonics

Purdue University researchers have

devised miniature transducers that are implanted in tumors to generate oxygen, boosting the killing power of radiation and chemotherapy treatments

The devices get electrical power from sonic waves beamed at them from outside the patient’s body

ultra-The technology is designed to treat solid tumors that have little oxygen at their cores Radiation therapy needs oxygen to be effective, so such tumors, which character-

RS# 121

Hydrogen

Oxygen

Ultrasonic wave

Rectifying circuit

Ultrasonic receiver Ion-exchange

membrane

Exposed electrodes

SEPTEMBER 22, 2011

GORE® Wire and Cable

When reliability, durability, and performance can be compromised

by harsh environments, GORE ® Wire and Cables offer the best solution.

gore.com/electronics

When failure

is not

an option

WIRE AND CABLE

ize pancreatic, cervical, and liver cancers, have proven hard to treat

Purdue’s implantable micro oxygen generator harvests energy

from an incoming 2.15-MHz ultrasonic wave using a

lead-zirconate-titanate (PZT) transducer Electrical energy from the PZT transducer

is rectified to a dc voltage that is then applied to the water in the

in-terstitial fluid through a set of interdigitated electrodes This

sepa-rates oxygen and hydrogen in the water in a chemical process

called electrolysis

The oxygen generators were created at Purdue’s Birck Nanotechnology Center Researchers have tested the devices

in pancreatic tumors implanted in mice, showing they

gener-ated oxygen, which led to the tumors shrinking faster under

treatment The devices are slightly less than 1-cm long and are

inserted into tumors with hypodermic opsy needles

bi-Findings are detailed in a research paper appearing online in Transactions on Bio-medical Engineering The paper was writ-ten by research assistant professor Teimour Maleki, doctoral students Ning Cao and

Seung Hyun Song, Indiana University

School of Medicine assistant professor of

clinical radiation oncology Song-Chu (Arthur) Ko, and professor of

electrical and computer engineering and biomedical engineering

Babak Ziaie MD

National lab teams with China to

develop clean energy

on R&D for clean

energy The institute

is the research wing of

Huaneng Power

Interna-tional Inc., the world’s

larg-est power company The two

organizations will concentrate

on carbon capture and

sequestra-tion (CCS), enhanced oil recovery,

and shale gas

Livermore scientists will contribute their expertise in CCS, material science, and energy-systems analysis

Huaneng operates Gen, the first large-scale coal-fueled power plant that uses CCS

Green-The company also operates the largest CCS pilot plant That plant uses 15 MW

to capture about 120,000 tons of CO2annually The com-pany plans on scaling

up CCS at the plant so it can ter 2.5 million tons of CO2 per year

seques-CCS separates CO2 from the flue stream of industrial and power plants, compresses it, and stores

it underground in deep cal formations, thus preventing it from entering the atmosphere MD

MT2A Miniature String Pot

CRASH & FLIGHT TESTING!

GREAT TECHNOLOGY IS ONLY GREAT

IF IT CAN BE DELIVERED.

www.linearmotiondelivered.com

Design Now, Deliver Now.

REPORTER’S NOTEBOOK

plug in to outside power As trash accumulates, an

internal photoelectric cell senses when the bin is full

and triggers a compaction cycle When the receptacle

needs to be emptied, it sends a text message via

wire-less link to a pickup crew

Typical users of the trash bin include national parks,

beaches, universities, towns, and major cities The city

of Philadelphia, for example, replaced 700 ordinary

receptacles with 500 solar-powered trash compactors

and 210 single-stream recycling units The city now

collects trash only five times per week instead of 17

Collection takes nine workers on one shift instead of

33 on three shifts, as was formerly the case MD

Roland Neel noted a jor reduction in freight costs and a significant reduction in broken and damaged-goods charges from retailers He says PET lets the brand maintain its glasslike appearance for

ma-a premium-quma-ality imma-age while improving the pack-aging’s carbon footprint and recyclability

The 32-oz style bottle is the first

decanter-of its kind to use PET The 50-gm container can be filled with barbecue sauce that is 140°F It is also less prone to tipping on the filling line, thanks to a rigid base A hot-fill version can be filled with liquids up to 185°F

The 12-oz ring-neck bottle includes a diaphragm in the base that draws upward as the liquid within cools and creates a vacuum The diaphragm takes the place

of side panels other manufacturers use to compensate for vacuum The panels can make it difficult to smoothly label the bottles But Amcor’s version can carry a large, uninterrupted label panel around its circumference MD

Trash compactor… continued from page 22 PET… continued from page 23

RS# 124

Converting 12 and 32-oz sauce containers from glass to PET saved Mrs Griffin’s Barbecue Sauce shipping and breakage costs while preserving its high-quality image The containers can be filled at ambient

barbecue-or elevated temperatures and are easily labeled.

Visible in this view of the Solar Compactor is the clear molded

cover that protects the unit’s solar cells.

ThomasNet.com’s new semantic search technology will transform your product

and supplier discovery process Our revolutionary product finder understands

syntax patterns—so unlike most search engines, it not only gives you product

results containing specified attributes, but also further defines your need with

the help of its pre-navigation feature

ThomasNet.com/ProdSearch FIND THE EXACT OEM OR MRO PRODUCT YOU NEED.

RS# 125

IT’S NOT NEXT GENERATION TECHNOLOGY

IF THE DELIVERY SKIPS A FEW GENERATIONS.

Design Now, Deliver Now.

REPORTER’S NOTEBOOK

Probe monitors the lining inside

tokamak reactors

Engineers and nuclear scientists

have a host of challenges to

over-come before they build a working

model of a tokamak, a

fusion-pow-ered reactor that could generate 10

times the power of a conventional

fission reactor using fuel derived

from seawater One problem is

con-structing reactor walls and coatings

that stand up to interactions with

the plasma contained within These

plasmas can reach 100 million

de-grees Celsius, hot enough to

physi-cally change materials they come

near

To help surmount that challenge,

engineering students at Purdue

Uni-versity, led by professor Jean Paul

Allain, constructed a materials analysis

particle probe, or MAPP MAPP will

collect information on how materials

change when exposed to plasmas and

how those interactions correlate with

changes in the plasmas It is hoped

this data will lead researchers to

mate-rials that can line tokamak reactors

MAPP will be used on the experimental reactor at

Princeton University, the country’s largest

spheri-cal tokamak, known as the National Spherispheri-cal Torus

Experiment The new device replaces the previous

investigational method of lining inner reactor walls

with test specimens of materials that are removed

in the materials lining the inside of fusion reactors.

and checked after a year of operation and hundreds

of tokamak experiments MAPP will let researchers see results and changes in materials just minutes after each experiment The new probe will also let scientists from anywhere in the world program and use it through a Web site based at Purdue MD

REPORTER’S NOTEBOOK

Adhesives let shooters improve aim with

tracersPeople outside of the military generally had not had the opportu-nity to shoot tracer bul-lets until engineers at

Hallam Inc., Hunstville,

Tex., developed Glow Ammo It consists of a small “dot” of chemicals applied to the back

of a bullet by ers, i.e., shooters who,

reload-in essence, construct their own bullets When the bullet is fired, the chemicals capture en-ergy from the expand-ing gases and convert it into light, according to the company This lets the shooter track the round and see where it hits When used properly, the tracer lets shooters adjust their next shot and get closer to the target

Unlike conventional tracer rounds, which are almost exclusively used

by the military, Glow Ammo is a cold tracer

There is no potentially dangerous fire or flame

Hallam invested over three years to make sure the tracer dots are safe and effective Then it worked with Fabrico,

Kennesaw, Ga., a pany with expertise in die cutting, adhesives, and liner materials, to make Glow Ammo easy for re-loaders to use

com-Fabrico devised an adhesive that would affix the dot to the bottom of a bullet prior to it being seated

in a casing The adhesive keeps the tracer on the bullet for at least 18 months, if stored at room tem-perature For packaging, Fabrico came up with a liner material that worked well with Hallam’s manufactur-ing processes MD

RS# 127

a grain (0.065 gm) and does not affect bullet velocity or trajectory The company makes Glow Ammo for 9-mm and 40 and 45-caliber handgun ammunition The price for

255 Glow Ammo dots is about $50.

Call us at 1-888-260-7466 or fax us at 516-771-6444

or Email us at sales@ondrives.us See us at www.ondrives.us/gears.htm

We use gears, not just make them! Solutions provided!

+ ISO 9001:2008 certified

+ Quick and timely shipments + Standards and customs + Gears, pinions, worms, worm gears

We manufacture gearboxes of all types and know how to use gears

of all kinds Solving gearing problems is part of our DNA.

KissSoft software: gearing and analysis, AutoDesk Inventor: design

Electronic brakes note

telltale signs of panic: The

Mercedes-Benz SL coupe/

roadster uses a computer to

tell four valves exactly how hard to

hit the brakes An electrically driven

hydraulic pump and high-pressure

reservoir help put full brake pressure at each wheel, eliminating bulky vacuum-brake boosters

The brakes recognize early signs

of an emergency and react Pressure

in the brake connectors rises, moving the pads onto the discs, permitting instant reaction when the brakes are pressed

30 YEARS AGO — 1981

New way to make big plastic parts:

Molds for plastic aircraft components can be rapidly and economically produced by a new method, says

TAFA Metallisation Inc., Bow, N H

Based on high-velocity arcspraying, the process

is intended for large (over 100 ft2) prototype molds for runs of 400

to 500 units and molds for production runs up to 20,000 units, depending on pres-sure and temperature The process can be used for composites, vacuum forming, rotational molding, SMC, RIM tooling, and injection molding Molds are formed by spraying zinc on model material, such as wood, plastic, leather, and wax, to exactly reproduce both shape and finish With arcspray, zinc can be applied at 30 lb/hr and

a mold-wall thickness of 1/8 in can

be built up rapidly The metal shell is then backed by a special laminating paste with compatible expansion characteristics

50 YEARS AGO — 1961

Plastic sandwiches in a new

refriger-ated freight car can maintain any temperature from –10 to 70°F The three-layer panels which line the car are made of Cycolac polymer,

a rigid ABS plastic

from Marbon

Chemical Div

of Borg-Warner Corp.; Dylite expandable polystyrene

insulation from Koppers Co.; and a

¼-in plywood back These panels duce weight of the refrigerator car and, because they are only 6½-in.-thick, add

re-451 ft3 of space to the car’s capacity MD SEPTEMBER 22, 2011

MACHINE Design.com

32

Avago Technologies new generation optocouplers, ACPL-x6xL series

off er signifi cant power effi ciency improvements for industrial communication interfaces With 35 years

of experience in digital optocoupler design, Avago delivers quality you can count on

www.avagoresponsecenter.com/608

© 2011 Avago Technologies All rights reserved.

Technology You Can Trust

Ultra Low Power Digital Optocouplers in Industrial Communication Interfaces

90% less power than standard optocouplers 40% lower power than alternative digital isolators

To request a free evaluation board go to:

REPORTER’S NOTEBOOK

AWARDS

The 9440 Remote Area Lighting

System (RALS) from Pelican

Products, Torrance, Calif., was

honored in the Electronics

category during the recent Good

Design Award Show in Chicago

Hosted by the Chicago

Athenaeum – Museum of Architecture and Design and The European Centre – Architecture Art Design and Urban Studies, the event

honored the world’s foremost designers and manufacturers from

the previous year The Pelican 9440 RALS is a portable LED area light It features 10 next-generation LEDs and a beam spread of 120° that effectively lights a large area The light is powered by a maintenance-free, nickel-metal-hydride

rechargeable battery As a result,

it runs silently, has no power cord (which eliminates trip-hazards), and emits no toxic fumes

Applied Industrial Technologies,

Cleveland, received two prestigious

awards from Eastman Chemical

Co., Kingsport Tenn The awards

are part of the Eastman Supplier Excellence Program (ESEP) for 2010 The Eastman Supplier Excellence Award signifies consistent performance in furnishing Eastman with high-quality materials and on-time shipping performance, while working on Eastman’s behalf to improve efficiency and competitiveness in today’s market.The Eastman Innovation Award recognizes that Applied has made other contributions, such

as assisting numerous customers and helping to proactively manage inventory levels for optimum efficiency

ONLINE MAGAZINE

The latest edition of Lighting Solutions TechZone magazine is

now available online from

Digi-Key Corp., Thief River Falls, Minn.,

at www.digikey.com/magazine The LED-driver-themed issue features articles on ambient-light sensing, transformative LED technologies, and more, written by top industry professionals and representatives from lighting suppliers such as

LEDIL, Maxim, and Molex, as

well as a piece from the National

Institute of Standards and Technology.

PERSONNEL

Fabrico, Kennesaw, Ga., has

appointed Mark White as a Technical Sales Representative to expand the company’s printing opportunities in North America MD

COMPANY NEWS

RS# 130 SEPTEMBER 22, 2011 MACHINE Design.com

34

Associated Spring Raymond - USA

We are an ISO/TS 16949:2009 and ISO 9001: 2008 certified company ©2011 Barnes Group Inc SPEC® is a trademark of Barnes Group Inc.

The difference is in the details.

Get our 2011 catalog See the difference.

We are the leading source for stock precision components, and we

take our responsibility very seriously Our compression, extension and

torsion springs and spring washers are the highest quality, engineered

for superior performance And we continue to introduce new products

that meet these high standards – for example, our complete line of

316 Stainless Steel compression, extension and torsion springs,

Inconel® compression springs, and new lines of gas struts

But the difference is also in our extra service Rapid shipping from

facilities in the Americas, Europe and Asia Custom work capabilities

for materials, coatings, kitting and secondary processes Ordering

and shipping available 24/7/365

Look closely at Associated Spring-Raymond SPEC®

Call 1.800.872.7732 or visit asraymond.com/spec-spd/ for

our new product catalog

RS# 131

Oct 13-15 — The 7th annual

Comsol Conference brings

together engineers from a

broad spectrum of industries

to see the latest in

state-of-the-art multiphysics simulation

The program includes user

presentations, hands-on minicourses, tutorials, exhibition, poster session, keynotes, an awards banquet, and more The event will take place at the Boston Marriott Newton in Newton, Mass For more information, go to http://www

comsol.com/conference2011/usa/

SHPE CONFERENCE 2011

Oct 26-30 — The Society of

Hispanic Professional Engineers

(SHPE) will hold its annual conference at the Anaheim Convention Center in California The multifaceted conference offers a wide range of programs for middle and high-school youth, university students and professionals in STEM fields Highlights of the conference include the following: Career Expo; Professional Program features certification courses and concentrated tracks in business development and green engineering; Graduate Program includes seminars designed to nurture the development of future faculty and researchers; Undergraduate Program filled with technical and experiential learning opportunities for university students; and Pre-College Symposia

— An extensive program that exposes Hispanic youth in grades six through 12 to STEM subjects and career opportunities

For more information, go to http://conference.shpe.org/shpe2011 Schools or individual middle or high-school students interested

in attending the Pre-College Symposia can register at www.shpefoundation.org

TUBE BENDING CONFERENCE

Nov 24-25 — The 4th Dortmund Tube and Profile Bending Colloquium DORP2011 will

be held at the Dortmunder Westfalenhallen in Germany The conference covers the increasing demands on bent parts — 3D profile bending with very small radii, complicated geometries, and use of high-strength materials The forum lets attendees exchange experiencesbetween users, machine manufacturers, and university researchers There will be lectures, stimulating discussions, and an intense exchange of experiences and views between industry and science on an international level More information visit

www.iul.eu/dorp2011 MD

MEETINGS & SHOWS

RS# 132 SEPTEMBER 22, 2011 MACHINE Design.com

36

A E R O S P A C E C E R T I F I E D S E A L I N G S O L U T I O N S

FAX 716.684.8302 • email: info@applerubber.com • 310 Erie Street, Lancaster, NY 14086-9504

You buy direct from our USA plant.

In the demanding world of aerospace manufacturing, there is no margin for error

A company’s commitment to quality is paramount Apple Rubber Products is proud

to be one of the select few manufacturers whose quality management system has

achieved the highest standards set forth by the global aerospace industry:

AS9100 Certifi cation

www.applerubber.com 1.800.828.7745

+1.716.684.6560

We’ve earned our wings.

RS# 133

ADVANCED MANUFACTURING

Resources:

Cimatron Group, www.cimatron.com

Software helps build large, complex molds

There are many flavors of engineering

soft-ware that target specific manufacturing

processes For example, CimatronE CAD/

CAM software from the Cimatron Group in

Israel, lets users handle all aspects of

mold-making, from quoting through design and

manufacturing As typical with these kinds

of packages, users can implement individual

modules — which include those for data

import, quoting, parting, preliminary design,

mold tool design, and NC programming —

one or two at a time or all at once Users with

all the modules can conceivably get an entire job

done in a single setting These kinds of targeted

packages tend to be more efficient because users

need not struggle to construct the unique features

of a mold with general-purpose CAD, a tedious

pro-cess at best

The modules follow a standard mold-design

workflow Here is a sampling of the modules:

The Data Import module heals and stitches data

and converts files from all standard formats such as

DWG, IGES, and Parasolid The Quoting module

in-cludes a special tool that spots undercuts and other

areas needing additional work It also estimates the

cost of the mold base including primary

mecha-nisms such as sliders and runners

The Parting module lets users modify models

for manufacturability It also includes tools for

vi-sualizing parting lines and simulating motion The

Preliminary Design module lets users create quick

3D designs for customer approvals It lets users

de-sign any size mold with thousands of surfaces and

components and can handle multicavity and family

molds The module generates an initial BOM, so

us-ers can order material early and begin machining

while they wait for final design approval

The Mold Tool module validates designs using

measurement, analysis, and collision-detection

tools The module lets multiple users

simultane-ously work on the same assembly, helping speed

design It includes a library of standard catalog

parts and user-defined mechanisms such as sliders

and lifters The module also analyzes engineering

change orders (ECO) and applies local changes

within seconds, even in assemblies that are close

to completion The Ejection Systems Design module

can place hundreds of ejectors in a single step, and

then analyze the plates they will pass through and

handle the trimming The module lets users insert

ready-to-use ejector mechanisms from any

stan-dard catalog

The Cooling System Design module simplifies

the design of complex cooling mechanisms and all

the necessary cooling elements such as channels, plugs, connectors, and baffles The Drawing module eliminates repetitive manual steps by automating the placement of center lines, coordinate labels, and other drawing elements The Runner Designmodule quickly creates efficient runners and trans-fers the runner path data to the user’s NC program The NC Programming module includes CAD with good surfacing capabilities which provide the best machining results

The Automated Drill module can recognize hundreds of holes in seconds and then assign the appropriate drilling sequence Working with other modules, it uses hole properties assigned during the tool design phase, such as thread, accuracy, and surface quality, helping speed design and eliminate errors

The Efficient Roughing module lets mers preview machining results in seconds to more easily optimize machining strategies For highly productive high-speed milling (HSM), the module generates an all-round toolpath with constant tool load, trochoidal milling, advanced clean between passes, and efficient rough between layers The High Quality Finishing module helps generate good surfaces that don’t need polishing

program-Another manufacturing module is Advanced cro Milling It includes a large library of machining strategies that support a complete range of cut-ters including tapered cutters, lollipop tools, and slot-mill cutters The Post-Processor Support module includes a library of post processors for all three and five-axis machine tools as well as all leading controllers Advanced simulation generated with the G-code permits simulation of the real-world machine kinematics and toolpath motion Other modules target wire-EDM programming and elec-trode manufacturing MD

Mi-Edited by Leslie Gordon

SEPTEMBER 22, 2011 MACHINE Design.com

38